Plasma assisted gasification system with internal syngas heater

ABSTRACT

A controlled zone gasification reactor for a plasma assisted gasification reaction system is disclosed for converting fuel, such as, but not limited to, biomass, to syngas to replace petroleum based fuels used in power generation. The system may be a modular system housed within a frame facilitating relatively easy transportation. The system may include a reactor vessel with distinct reaction zones that facilitate greater control and a more efficient system. The system may include a syngas heater channeling syngas collected downstream of the carbon layer support and to the pyrolysis reaction zone. The system may also include a syngas separation chamber configured to produce clean syngas, thereby requiring less filtering. The system may further include an agitator drive assembly that prevents formation of burn channels with in the fuel.

FIELD OF THE INVENTION

The invention relates in general to gasification systems and, moreparticularly, to gasification systems capable of using waste products asfuel to form clean synthetic gas (syngas) that is useful for powergeneration.

BACKGROUND OF THE INVENTION

Gasification systems have been used for power generation by convertingbiomass fuel sources into combustible gases that contain nearly all ofthe energy of the biomass. The gasification systems convert carbonaceousmaterials, such as coal, biomass, biofuel, carbon dioxide, hydrogen andpetroleum, into charcoal, wood-oils, and tars using both combustion andpyrolysis with a controlled amount of oxygen or steam. The gasificationsystems produce syngas, which is used as a fuel within engines, such asinternal combustion engines and turbine engines. Syngas may be combustedat higher temperatures than other fuels courses, thereby making internalcombustion of syngas potentially more efficient than other fuel sources.

A challenging aspect of using gasification systems for power generationfrom waste fuel sources is efficiently producing power while handlingthe waste products developed within the systems. The highly efficientmethod of converting syngas to electric power is offset by powerconsumption in waste fuel preprocessing and gas cleaning. Thegasification byproducts including tars must be filtered from the syngasbefore the syngas can be burned in an engine, otherwise, the life of theengine will be greatly shortened.

Gasification systems used for power generation systems typically have alarge footprint, such as an acre or more, and are typically constructedon-site. As such, skilled tradesman are required to construct and oftento operate such a gasification system, which limits the locale in whichthe conventional gasification systems may be constructed efficiently.The costs associated with constructing and operating conventionalgasification systems in remote locales often outweighs the benefit ofthe power generated. Thus, a gasification system is needed that producessyngas efficiently with few contaminants and overcomes the challenges ofremote site construction and operation.

SUMMARY OF THE INVENTION

A plasma assisted gasification system having a controlled zonegasification reactor is disclosed for converting fuel, such as, but notlimited to, biomass, to electricity. The gasification system can createelectricity from biomass by producing syngas to replace the need forpetroleum based fuels to engines, such as, but not limited to, dieselengines and turbine engines. The engines may operate at least partiallyon the syngas supplied by the syngas separation chamber. Thegasification system may be a modular system housed within a framefacilitating relatively easy transportation. The gasification system maybe a modular syngas powered power generation system that facilitateseasy shipment over land, sea, rail, or air, including being air droppedto any destination. The frame may have any appropriate configurationnecessary to facilitate transportation of the system from manufacturingsite to on-site location and between operation sites.

The plasma assisted gasification system may include a reactor vesselhaving at least one fuel inlet, a pyrolysis reaction zone, a combustionreaction zone and a carbon layer support, wherein the pyrolysis reactionzone may be positioned above a combustion reaction zone, and thecombustion reaction zone may be positioned above a carbon layer support.The pyrolysis reaction zone may be positioned between an inner surfaceof the reactor vessel and an outer surface of a conduit forming a fuelinlet, whereby the pyrolysis reaction zone may include at least oneplasma torch. The pyrolysis reaction zone may include a downstreamshield extending at least partially from an inner surface of the reactorvessel towards the conduit forming the fuel inlet. The combustionreaction zone may be defined by at least one rotatable burner on anupstream side of the combustion reaction zone, wherein the rotatableburner is configured to rotate within the reactor vessel to reduce theformation of burn channels in fuel held in the reactor vessel. The useof the burners define the combustion reaction zone. The reactor vesselmay also include an ash collection zone positioned downstream from thecarbon layer support.

The system may also include an engine, which may be, but is not limitedto being, a turbine engine and a diesel engine, that operates at leastpartially on the syngas supplied by the syngas separation chamber and anelectric generator in communication with the engine and configured togenerate electricity from rotational movement of components of theengine. The gasification system may include a syngas heater channelingsyngas collected downstream of the carbon layer support and to thepyrolysis reaction zone.

The gasification system may also include an impure syngas recyclerpositioned in the reactor vessel for routing syngas together withcontaminants from a region downstream of the carbon layer support to thecombustion reaction zone. The syngas recycler may be formed from asyngas separation chamber and at least one burner. The syngas separationchamber may be positioned within the reactor vessel to separatecontaminants created during combustion in the combustion chamber fromthe syngas. The gasification system may also include a syngas recyclerpositioned in the reactor for routing syngas together with contaminantsfrom a region downstream of the carbon layer support to the combustionreaction zone. The syngas recycler may include a turbine positionedwithin a turbine assembly upstream from the syngas separation chambersuch that during operation separates syngas from contaminants in thesyngas such that the contaminants are located near an outer walldefining the syngas separation chamber and relatively uncontaminatedsyngas is located closer to a longitudinal axis of the syngas separationchamber. Contaminated syngas may be passed to the burners of theagitator drive assembly, where the contaminants are burned. The turbineassembly may be formed from a plurality of sidewalls forming a chamberthat extends from the carbon layer support to an outer wall forming thereactor vessel of the reaction chamber. At least one of the plurality ofsidewalls may have at least one inlet therein.

The gasification system may include an agitator drive assemblypositioned in the reactor vessel extending into the combustion reactionzone and defining at least a portion of the combustion reaction zonewith one or more burners. The burner may be rotatable within the reactorvessel to prevent formation of burn channels within the fuel. Thegasification system may include a plurality of rotatable burners thatextend radially outward from an outer surface of the conduit forming aportion of the agitator drive assembly. In one embodiment, the burnermay be rotated by rotating the agitator drive assembly. As such, theconduit forming a portion of the agitator drive assembly may alsoinclude a drive gear attached to a bottom portion of the agitator driveassembly and may be configured to drive the agitator drive assembly at arotational speed of less than about two revolutions per minute. Thegasification system may include a syngas separation chamber positionedin a hollow portion of the agitator drive assembly configured toseparate contaminants from syngas such that syngas with contaminants arepassed into the burner to remove the contaminants from the system. Avortex inducing device, such as, but not limited to a turbine, may belocated upstream from the syngas separation chamber to create a highspeed vortex sending contaminants in the syngas to the outer walls. Thecontaminants are routed to the through the burners to the combustionzone and the syngas is routed toward the engine.

The frame may be configured to form a trailer upon which at least aportion of, or the entirety of, the gasification system may be housed.In at least one embodiment, the frame may be a trailer sized andconstructed in conformity with applicable laws such that the trailer maybe pulled on public roadways. In at least one embodiment, components ofthe system, including, but not limited to, the reactor vessel, theengine, the generator, and the syngas filter may be positioned on theframe such that when the system is positioned in a stowed position, thecomponents of the system are contained within the frame such that theframe may be towed on a highway without components being placed in riskof being destroyed. The frame may also be inserted into a fully enclosedshipping container. In at least one embodiment, the frame, in a stowedposition, may have outer dimensions less than inner dimensions ofstandard 40 foot shipping container and therefore, may be configured tofit within a 40 foot long shipping container.

One or more of the plasma torches may be positioned such that an exit ofthe plasmas torch is directed partially radially inward, nontangentialand nonradial in a plane orthogonal to a longitudinal axis of thereactor vessel, and may be positioned in a downstream directionnonparallel to the longitudinal axis, thereby, during use, forming ahelical pathway of pyrolysis gas, during use, within the fuel containedin the reactor vessel. The plasma torch may be positioned in adownstream direction nonparallel to the longitudinal axis such that theplasma torch is positioned between about five degrees and 20 degreesfrom a plane orthogonal to the longitudinal axis of the reactor vessel.

The gasification system may include an agitator drive assemblypositioned in the reactor vessel extending into the combustion reactionzone and defining at least a portion of the combustion reaction zonewith one or more burners. The burner may be rotatable within the reactorvessel to prevent formation of burn channels within the fuel. Thegasification system may include a plurality of rotatable burners thatextend radially outward from an outer surface of the conduit forming aportion of the agitator drive assembly. In one embodiment, the burnermay be rotated by rotating the agitator drive assembly. As such, theconduit forming a portion of the agitator drive assembly may alsoinclude a drive gear attached to a bottom portion of the agitator driveassembly and may be configured to drive the agitator drive assembly at arotational speed of less than about two revolutions per minute. Thegasification system may include a syngas separation chamber positionedin a hollow portion of the agitator drive assembly configured toseparate contaminants from syngas such that syngas with contaminants arepassed into the burner to remove the contaminants from the system.

A syngas exhaust conduit may be positioned within the agitator driveassembly and may have an inlet positioned upstream from an inlet to theburner, whereby the inlet to the syngas exhaust conduit may bepositioned radially inward from inner walls forming the syngasseparation chamber and the inlet to the at least one burner may bepositioned radially outward from the syngas exhaust conduit. In such aposition, syngas free of contaminants may be passed through the syngasexhaust conduit to an engine, and the syngas containing contaminants maybe sent to the burner to be recycled to remove the contaminants. In atleast one embodiment, the agitator drive assembly may include aplurality of burners that extend radially outward from an outer surfaceof the conduit forming a portion of the agitator drive assembly. Theagitator drive assembly may also include one or more ambient airsupplies that includes an outlet in direct fluid communication with theburners upstream from the burner outlet. Air may be supplied to thecombustor chamber if needed.

The gasification system may also include a fuel dryer in communicationwith and positioned upstream from the plasma assisted gasificationreaction chamber. The fuel dryer may be positioned upstream from thefuel inlet to the reactor vessel. An exhaust gas inlet in the dryer mayplace an exhaust from the engine in fluid communication with the fueldryer such that exhaust gases may be passed to the dryer to dry thefuel. The fuel inlet to the reactor vessel may be sealed with fuelpositioned in the fuel inlet and exhaust gases from the engine. Thegasification system may also include a fuel shredder in communicationwith and positioned upstream from the fuel dryer to shred the fuelbefore being feed to the fuel inlet.

The gasification system may also include one or more syngas filters influid communication with the plasma assisted gasification reactor vesseland positioned downstream from the carbon layer support and upstream ofthe engine. In one embodiment, the syngas filter may be formed from awater based scrubber that quickly quenches the syngas after formation tolimit the formation of NOx and to remove other contaminants before beinginjected into an engine.

The gasification system may also include a syngas heater for heating thesyngas before being passed to the engine. In at least one embodiment,the syngas heater may be positioned in the pyrolysis reaction zone suchthat heat from the pyrolysis reaction zone heats syngas flowing throughthe syngas heater. The syngas heater may be formed from at least oneconduit in direct fluid communication with the syngas collection chamberbetween the carbon layer support and the ash collection zone. Theconduit forming the syngas heater may be formed from a conduit that ispositioned at least in part radially outward from a fuel inlet conduitforming at least a portion of the at least one fuel inlet of the reactorvessel. The conduit forming the syngas heater may have at least oneoutlet in the pyrolysis reaction zone such that the syngas is exhaustedinto the pyrolysis reaction zone. The syngas heater conduit may beformed from at least one exhaust conduit having a support bearing thatbears on an outer surface of the fuel inlet conduit forming at least aportion of the at least one fuel inlet of the reactor vessel. The syngasheater conduit may be rotatable about the outer surface of the fuelinlet conduit. In at least one embodiment, the syngas heater conduit maybe coupled to the agitation device assembly and may thus be rotatable.

An advantage of the gasification system is that household rubbish may beused as shredded fuel to create syngas, thereby reducing the diesel fuelconsumption in power generation by up to 90 percent and eliminatingrubbish with minimal contaminant discharge in the air.

Another advantage of this system is that the gasification systemsubstantially reduces contaminates in the syngas that is produced,thereby producing a syngas that requires less filtering and is morereadily usable in an engine without requiring extensive filtering.

Yet another advantage of this system is that the gasification systemproduces syngas with fewer contaminates, thereby resulting in lesscontamination buildup in an engine in which syngas is used.

Another advantage of this invention is that the syngas heater increasesthe efficiency of the engine without negatively impacting the reactorvessel.

These and other advantages can be realized with a system in accordancewith aspects of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic view of the plasma assisted gasification system.

FIG. 2 is a partial cross-sectional front view of the reactor vessel ofthe plasma assisted gasification system.

FIG. 3 is a partial cross-sectional upward viewing perspective view ofthe reactor vessel of the plasma assisted gasification system.

FIG. 4 is a partial cross-sectional downward viewing perspective view ofthe reactor vessel of the plasma assisted gasification system.

FIG. 5 is a partial cross-sectional front view of the agitator driveassembly.

FIG. 6 is a partial top view of the agitator drive assembly.

FIG. 7 is a perspective view of the turbine configured to be positionedwithin the turbine assembly in the agitator drive assembly.

FIG. 8 is an exemplary site plan for the plasma assisted gasificationsystem.

FIG. 9 is a side view of the plasma assisted gasification system in astowed position.

FIG. 10 is a side view of the plasma assisted gasification system in anoperating position.

DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION

Aspects of the present invention relate to gasification components,systems and associated methods that can enhance the performance of aplasma assisted gasification system. Embodiments according to aspects ofthe invention are shown in FIGS. 1-10, but the present invention is notlimited to the illustrated structure or application. Rather, thefollowing detailed description is intended only as exemplary.

As shown in FIGS. 1-10, a plasma assisted gasification system 10 havinga controlled zone gasification reactor 12 is disclosed for convertingfuel 142, such as, but not limited to, biomass, to electricity. Thegasification system 10 can create electricity from biomass by producingsyngas to replace the need for petroleum based fuels to engines, suchas, but not limited to, diesel engines and turbine engines 108. Theengines 108, as shown in FIGS. 1, 9 and 10, may operate at leastpartially on the syngas supplied by the syngas separation chamber. Thegasification system 10 may be a modular system housed within a frame 14facilitating relatively easy transportation. The gasification system 10may be a modular syngas powered power generation system 10 thatfacilitates easy shipment over land, sea, rail, or air, including beingair dropped to any destination. The frame 14 may have any appropriateconfiguration necessary to facilitate transportation of the system 10from manufacturing site to on-site location and between operation sites.

As shown in FIGS. 2-4, the plasma assisted gasification system 10 mayinclude a reactor vessel 16 having at least one fuel inlet 44 and havingdistinct reaction zones 18, including, but not limited to, a pyrolysisreaction zone 20, a combustion reaction zone 24 and a carbon layersupport 32. The pyrolysis reaction zone 20 may be positioned upstream ofthe combustion reaction zone 24, and the combustion reaction zone 24 maybe positioned upstream of a carbon layer support 32. The pyrolysisreaction zone 20 may be positioned between an inner surface 48 of thereactor vessel 16, an outer surface 50 of a conduit 52, also referred toas a fuel hopper, forming the fuel inlet 44, and a surface of the fuel142, as shown in FIG. 2. The pyrolysis reaction zone 20 may include atleast one plasma torch 22. The pyrolysis reaction zone 20 may include adownstream shield 60 extending at least partially from an inner surface48 of the reactor vessel 16 towards the conduit 52 forming the fuelinlet 44. The shield 60 prevents the fuel 142 from filing the pyrolysisreaction zone 20. The pyrolysis reaction zone 20 may be formed radiallyoutward from the conduit 52 forming the fuel inlet 44. The combustionreaction zone 24 may be defined by at least one rotatable burner 26 onan upstream side 28 of the combustion reaction zone 24 such that therotatable burner 26 is configured to rotate within the reactor vessel 16to reduce the formation of burn channels in fuel 142 held in the reactorvessel 16. The use of the burners 26 define the combustion reaction zone24. The reactor vessel 16 may also include an ash collection zone 46positioned downstream from the carbon layer support 32.

As shown in FIGS. 2-4, the gasification system 10 may include one ormore plasma torches 22 positioned within the pyrolysis reaction zone 20.The plasma torch 22 may be positioned in any appropriate position. Inone embodiment, the plasma torch 22 may extend partially radiallyinward, and may be positioned nontangential and nonradial in a plane 56orthogonal to a longitudinal axis 54 of the reactor vessel 16, and theplasma torch 22 may be positioned in a downstream direction nonparallelto the longitudinal axis 54, thereby forming a helical pathway 58 ofpyrolysis gas, during use, within the fuel 142 contained in the reactorvessel 16. The plasma torch 22 may be positioned in a downstreamdirection nonparallel to the longitudinal axis 54 such that the plasmatorch 54 may be positioned between about 5 degrees and 20 degrees from aplane orthogonal to the longitudinal axis 54 of the reactor vessel 16.In at least one embodiment, as shown in FIGS. 1-4, the gasificationsystem 10 may include a plurality of plasma torches 22. The plasma torch22 may be any appropriate plasma torch, such as, but not limited to, aburner with a flame temperature of at least about 1,300 degrees Celsius,such as but not limited to plasma burners. The ultraviolet emissionsfrom the electrically charged flame helps to break up leftoverhydrocarbons (tars) in the syngas exit region of the reactor vessel 16.

The combustion reaction zone 24 may be positioned downstream from thepyrolysis reaction zone 20 and may be defined by at least one rotatableburner 26 on an upstream side 28 of the combustion reaction zone 24 andon the downstream side by burned fuel 142 resting on the carbon supportlayer. The rotatable burner 26 may be configured to rotate within thereactor vessel 16 to reduce the formation of burn channels in fuel 142held in the reactor vessel 16. In one embodiment, the gasificationsystem 10 may include a plurality of rotatable burners that extendradially outward from an outer surface 62 of the conduit 64 forming aportion of the agitator drive assembly 40, which is described in moredetail below.

The carbon layer support 32 may be positioned downstream from thecombustion reaction zone 24. The carbon layer support 32 may bepositioned upstream from an outer wall forming the reaction vessel 16and defining the ash collection zone. The carbon layer support 32 may beformed from a porous material. In at least one embodiment, the carbonlayer support 32 may be formed from grating, expanded metal, or othermaterial having holes enabling ash to pass through the carbon layersupport and collect in an ash collection zone 46 positioned downstreamfrom the carbon layer support 32. The carbon layer support 32 may beformed from materials capable of withstanding the high temperatureenvironment within the reactor vessel 16, the materials including, butnot limited to, stainless steel, ceramics, cooled piping, ornickel-chromium based superalloys, such as, but not limited to, INCONEL.

The gasification system 10 may include a syngas cleaning system 138 forremoving contaminants from the syngas before the syngas is passeddownstream of the reactor vessel 16 to the engine 108. The syngascleaning system 138 may be formed from a syngas recycler 136 positionedin the reactor vessel 16 for routing syngas together with contaminantsfrom a region downstream of the carbon layer support 32 to thecombustion reaction zone 24. The syngas recycler 136 may be formed froma syngas separation chamber 36 and at least one burner 26. The syngasseparation chamber 36 may be positioned within the reactor vessel 16 toseparate contaminants created during combustion in the combustionreaction zone 24 from the syngas.

The gasification system 10 may include an agitator drive assembly 40, asshown in FIGS. 2-4 and in detail in FIGS. 5 and 6, positioned in thereactor vessel 16, extending into the combustion reaction zone 24 anddefining at least a portion of the combustion reaction zone 24 with atleast one burner 26. A portion of the agitator drive assembly 40 may beformed from a conduit 64 that is hollow. The agitator drive assembly 40may be rotatable, and in at least one embodiment, may be rotatable aboutthe longitudinal axis 54 of the reactor vessel 16 to prevent theformation of burn channels in the fuel 142 in the reactor vessel 16. Theagitator drive assembly 40 may include a drive gear 68 attached to abottom portion of the agitator drive assembly 40. The drive gear 68 mayinclude reduction gears 70 configured to drive the agitator driveassembly 40 at a rotational speed of less than about two revolutions perminute. The agitator drive assembly 40 may be driven by a motor, suchas, but not limited to, an electric motor.

The agitator drive assembly 40 may include one or more burners 26, andin at least one embodiment, may include a plurality of burners 26. Theburners 26 may extend radially outward from the outer surface 62 of theconduit 64 forming a portion of the agitator drive assembly 40. One ormore of the plurality of burners 26 may be formed from a cylinder 72having an inlet 74 positioned at an inner surface 76 or positionedradially inward from the inner surface 76 of the conduit 64 forming theportion of the agitator drive assembly 40. The burner 26 may include anoutlet 78 formed from a diagonal cut through the cylinder 72, whereinthe outlet 78 faces away from the pyrolysis reaction zone 20. In oneembodiment, as shown in FIGS. 3 and 4, the agitator drive assembly 40may be formed from four cylindrical burners 26 extending radiallyoutward from the conduit 64 forming the portion of the agitator driveassembly 40. The agitator drive assembly 40 may include other number ofburners 26 other than four burners 26.

The agitator drive assembly 40 may include one or more ambient airsupplies 80 that includes an outlet 82 in fluid communication with atleast one of the plurality of burners 26 upstream from the burner outlet78. An inlet 84 of the ambient air supply 80 may be positioned outsideof the reactor vessel 16 to draw ambient air into the system 10 asneeded. As shown in FIGS. 2-6, the ambient air supply 80 may include oneor more ambient air supplies 80 in direct fluid communication with eachof the plurality of burners 26. In one embodiment, each ambient airsupply 80 may be a conduit 86. The conduit 86 may extend from an outersealing plate 88 through a carbon layer support seal plate 90 to eachburner 26. The conduits 86 may form four corners of an turbine assembly92. The conduits 86 may be coupled together with sidewalls 94 having oneor more orifices 96. The conduits 86 may extend through at least aportion of the combustion reaction zone 24 thereby forming an ambientair preheater that preheats the air before it is discharged into thecombustion reaction zone 24 for combustion.

As shown in FIG. 5, the gasification system 10 may include a syngasseparation chamber 36 for separating combustion products, such as tar,from the syngas. In at least one embodiment, the gasification system 10positioned in the hollow portion of the agitator drive assembly 40 maybe configured to separate contaminants from syngas such that syngas withcontaminants are passed into one or more burners 26. The syngasseparation chamber 36 may be positioned downstream from the burners 26.

In addition, the gasification system 10 may include a centrifuge device,which may be, but is not limited to being, a turbine 98, as shown inFIGS. 5 and 7, positioned within a turbine housing 100 upstream from thesyngas separation chamber 36. The turbine housing 100 may be positionedwithin the turbine assembly 92. During operation, the turbine 98 drawssyngas through the orifices 96 in the sidewalls 94 forming the turbineassembly 92. When assembled, the orifices 96 may be positioneddownstream of the carbon layer support 32 within the syngas collectionchamber 114 of the ash collection zone 46. The turbine 98 may beconfigured to operate at any appropriate speed and may be driven withmotor, such as, but not limited to, an electric motor or a hydraulicmotor. In at least one embodiment, the turbine 98 may operate between10,000 revolutions per minute (rpm) and 30,000 rpm. The turbine 98 mayhave any appropriate configuration with any appropriate number ofblades. The turbine 98 may be cooled, as appropriate, and in at leastone embodiment, may be oil cooled. The turbine assembly 92 may be formedfrom a plurality of sidewalls 94 forming a chamber that extends from thecarbon layer support 32 to the outer seal plate 88 positioned at thereactor vessel 16. The sidewalls 94, as shown in FIGS. 2-4, may includeone or more orifices 96 acting as inlets to the turbine 98. Duringoperation, use of the turbine 98 separates syngas from contaminants inthe syngas, such as, but not limited to, dust and tar, such that thecontaminants are located near an outer wall 102 defining the syngasseparation chamber 36 and relatively uncontaminated syngas is locatedcloser to a longitudinal axis 54 of the syngas separation chamber 36.Removal of the dust and tar from the syngas prevents the dust frombecoming molten in the pyrolysis reaction zone 20 and causing a problemin the engine 108 and the syngas filter 106. During use, the turbine 98may also provide a boost of about 2-5 pounds per square inch (psi) tothe syngas stream. The turbine 98 may create a multiplying effect on thereactor vessel 16.

A syngas exhaust conduit 104 may be positioned within the agitator driveassembly 40 to pass syngas having been cleaned in the syngas separationchamber 36 downstream to a syngas filter 106 and on to an engine 108.The syngas exhaust conduit 104 may have an inlet 110 positioned upstreamfrom an inlet 74 to the burner 26, whereby the inlet 110 to the syngasexhaust conduit 104 may be positioned radially inward from inner wallsforming the syngas separation chamber 36 and the inlet 74 to the burner26 may be positioned radially outward from the syngas exhaust conduit104. In such as position, syngas pulled through the turbine 98 isexhausted downstream and contaminants are centrifuged out. As such, thehigh rotational velocity of the syngas that passed through the turbine98 causes combustion byproducts, such as dust and tar, to be collectedalongside the inner surface of the wall forming the syngas separationchamber 36. The clean syngas located relatively close to thelongitudinal axis 54 of the syngas separation chamber 36 flows into thesyngas exhaust conduit 104, and the syngas together with the combustionbyproduct, tar, are passed into the inlets 74 of the burners 26.

As shown in FIGS. 2-4, the gasification system 10 may include one ormore syngas heaters 34 for heating the syngas before it reaches theengine 108. In one embodiment, the agitator drive assembly 40 mayinclude one or more syngas heaters 34 with an inlet 112 in fluidcommunication with the syngas collection chamber 114 of the ashcollection zone 46. The syngas heater 34 may be configured to heat thesyngas before the syngas is passed to the engine 108 to increase theefficiencies of the system 10. In at least one embodiment, the syngasheater 34 may be positioned in the pyrolysis reaction zone 20 such thatheat from the pyrolysis reaction zone 20 heats syngas flowing throughthe syngas heater 34. The syngas heater 34 may be formed from one ormore conduits 116 in direct fluid communication with the syngascollection chamber 114. The conduit 116 may extend from the syngascollection chamber 114 through the carbon layer support 32, through thecombustion reaction zone 24 and into the pyrolysis reaction zone 20. Asshown in FIGS. 2-4, the conduit 116 may extend from an end 118 of thesyngas exhaust conduit 104.

As shown in FIGS. 2-4, the conduit 116 forming the syngas heater 34 maybe formed from a conduit 116 that is positioned, at least in part,radially outward from the fuel inlet conduit 52 forming at least aportion of the fuel inlet 44 of the reactor vessel 16. The conduit 116forming the syngas heater 34 may have one or more outlets 120 in thepyrolysis reaction zone 20, and, in at least one embodiment, the conduit116 forming the syngas heater 34 may have a plurality of outlets 120 inthe pyrolysis reaction zone 20. As shown in FIGS. 2-4, the outlets 120in the pyrolysis reaction zone 20 may be formed from a plurality ofexhaust orifices 122 positioned in each of the outlets 120. As such,syngas is exhausted into the pyrolysis reaction zone 20 before beingpassed on to the engine 108. The conduit 116 may be formed from one ormore exhaust conduits 124 having a support bearing 126 that bears on anouter surface 50 of the fuel inlet conduit 52 forming at least a portionof the fuel inlet 44 of the reactor vessel 16. The exhaust conduit 124may be formed from a plurality of exhaust conduits 124, each extendingradially outward with an axially extending portion having a supportbearing 126 that bears on the outer surface 50 of the fuel inlet conduit52. In at least one embodiment, the plurality of exhaust conduits 124form four exhaust conduits 124 extending radially outward from a centralconduit, which may be, but is not limited to being, the syngas exhaustconduit 104, wherein the four exhaust conduits 124 are equally spacedfrom each other or positioned in another configuration.

As shown in FIGS. 9 and 10, the gasification system 10 may be a modularsystem housed within a frame 14 facilitating relatively easytransportation. The frame 14 may have any appropriate configurationnecessary to facilitate transportation of the system 10 from amanufacturing site to an on-site location and between usage sites. Theframe 14 may be configured to form a trailer upon which at least aportion of the system 10 or the entirety of the system 10 may be housed.In at least one embodiment, the frame 14 may be a trailer sized andconstructed in conformity with applicable laws such that the trailer maybe pulled on the roadways. In at least one embodiment, components of thesystem 10, including the reactor vessel 16, the engine 108, thegenerator 128, and the syngas filter 106 may be positioned on the frame14 such that when the system 10 is positioned in a stowed position, asshown in FIG. 9, the components of the system 10 are contained withinthe frame 14 such that the frame 14 may be towed on a highway withoutcomponents in risk of being destroyed. The frame 14 may also be insertedinto a fully enclosed shipping container. In at least one embodiment,the frame 14, in a stowed position, may have outer dimensions less thaninner dimensions of standard 40 foot shipping container and therefore,may be configured to fit within a 40 foot long shipping container. Assuch, the system 10 may be shipped over land, rail, sea, air and airdropped to any destination. Such mobility enables the system 10 to bebuilt in quality controlled facilities and shipped to the destination ofchoice for use, thereby enabling power to be made available to desolatelocations throughout the world. Such mobility of the system 10 couldmake it possible to make significant progress towards supplying costefficient power to villages, desolate populations and third worldcountries.

The system 10 may also include an electric generator 128 incommunication with the engine 108 and configured to generate electricityfrom a rotating drive shaft of the engine 108. The generator 128 mayhave be any appropriate generator and may be sized based on the powerdemands, the size of the reactor vessel 16 and other appropriatefactors. The engine 108, which may be, but is not limited to being, aturbine engine and a diesel engine, may operate at least partially onthe syngas supplied by the syngas separation chamber 36. The electricgenerator 128 may be in communication with the engine 108 and configuredto generate electricity from rotating components, such as the driveshaft, of the engine 108.

As shown in FIGS. 1-4, the gasification system 10 may include a fueldryer 130 in communication with and positioned upstream from the reactorvessel 16. In particular, the fuel dryer 130 may be positioned upstreamfrom the fuel inlet 44 to the reactor vessel 16. The heat source may beexhaust gases from the engine 108. In particular, an exhaust gas inlet132 in the dryer 130 places exhaust from the engine 108 in fluidcommunication with the fuel dryer 130 such that exhaust gases may bepassed to the dryer 130 to dry the fuel 142. As such, the fuel inlet 44to the reactor vessel 16 may be sealed with fuel 142 and exhaust gasesfrom the engine 108 sealing off the possible leakage of outside air withoxygen into the reactor vessel 16 through the fuel inlet 44. Inparticular, exhaust gases may be passed into the fuel 142 containedwithin the fuel dryer 130, and together the exhaust flowing upstreamthrough the fuel 142 positioned in the dryer 130 forms a dynamic sealfor the gasification system 10. Thus, a conventional rigid seal is nolonger required and fuel 142 may be more easily supplied to thegasification system 10 via hand or automated system without the use ofan airlock.

The automated fuel delivery system may be formed from one or moresystems having sensors that determine whether fuel contained within thefuel conduit 52 is within acceptable levels. If not, appropriatecorrection is made to add fuel into the fuel conduit 52. The fuel levelmay be monitored continuously, periodically, or at random time periods.The gasification system 10 may also include a fuel shredder 134 incommunication with and positioned upstream from the fuel dryer 130. Thefuel shredder 134 may be any appropriate device configured to shredfuel. The gasification system 10 may include multiple fuel shredders134, whereby at least some of the fuel shredders 134 may be adapted foruse with different type of fuels, such as rubbish, tires, wood chips andthe like.

The gasification system 10 may also include one or more syngas filters106 in fluid communication with the plasma assisted gasificationreaction chamber 16 and positioned downstream from the carbon layersupport 32. The syngas filter 106 may be formed from a water basedscrubber that quickly quenches the syngas after formation to limit theformation of NOx.

During use, the gasification system 10 may be transported to a usagesite, as shown in the exemplary site plan in FIG. 8. The gasificationsystem may be shipped via transportation modes, including, but notlimited to, truck, trailer, rail, air or ship. The gasification system10 may also be airdropped into remote locales where delivery by land orsea based transportation modes are not feasible. The gasification system10 may be tilted from a stowed position, as shown in FIG. 9, into anoperating position, as shown in FIG. 10. Due to the weight of thegasification system 10, the gasification system 10 should be placed overa pad, such as a concrete slab, with sufficient footer support toprovide an adequate foundation upon which the gasification system may beoperated.

During start-up of the gasification system 10, shredded fuel is placedinto the fuel dryer 130. The fuel may be, but is not limited to,rubbish, household waste, industrial waste, tires, and wood chips andliquid or gaseous fuels may be injected into the pyrolysis reaction zone20 or mixed with other fuels before being inputted into the reactorvessel 16. In some situations, shredded fuel may be provided, therebyeliminating the need to shred the fuel before use. The diesel engine 108may be run on diesel fuel at idle speed for about five to ten minutes towarm-up after which the diesel engine 108 may be run at operating speedand may generate electricity using the generator 128. With electricitybeing generated, the plasma torches 22 may be fired up. Additionally,the control systems and other subsystems of the gasification system 10,such as, but not limited to, the turbine 98 and the agitator driveassembly 40, may be fired. As the diesel engine 108 is operating,exhaust from the diesel engine 108 is routed to the fuel dryer 130 tobegin to dry the fuel. The reactor vessel 16 is heated with the plasmatorches 22. As the reactor vessel 16 and plasma torches 22 heat up,pyrolysis gas and steam begin to form and may be routed through thesyngas filter 106 and burned off using a flare 140. The flare 140 may befueled with any appropriate fuel, such as, but not limited to, propane,diesel fuel, a combination of both fuels, another fuel source or acombination of these listed fuels and other fuels. Once the chamberwithin the reactor vessel 16 is hot enough to generate usable syngas,the flared gas being burned in the flare 140 will ignite, therebyproducing a larger flame at the flare 140, which acts as a visualindicator. Such an increase in the size of the flare 140 is anindication that the syngas can be used in a diesel engine 108. Thediesel engine 108 may be syncronized to an external power grid orswitched onto an external power load. The desired power level may beset.

During operation, the content of oxygen in the engine exhaust gas shouldbe no more than two percent. Controlling the oxygen percentage in theexhaust gas controls the syngas production in the reactor vessel 16. Theflow of syngas to the flare 140 may be cutoff and rerouted to the fuelintake of the diesel engine 108 by closing a valve to the flare 140 andopening a valve to the fuel intake of the diesel engine 108. If thegenerator 128 operates under full load and only on diesel fuel, thegovernor of the diesel engine 108 should cut back diesel consumption toapproximately ten percent of the original consumption. The desired powerlevel may be established using a syngas valve. The fuel level in thefuel dryer 130 may be monitored visually, with sensors or otherappropriate method, and fuel may be added as needed with automated ormanual systems.

During operation, temperature levels, pressure levels, water supply andoil supply may be monitored. Bearing grease and oil may be supplied to adrive bearing on the agitator drive assembly 40. The temperature of thefuel dyer 130 may be set with a diesel engine exhaust bypass valve. Thepreheat temperature and the temperature in the pyrolysis reaction zone20 can be set by a reactor preheat valve in an exhaust bypass chamber.The height of the carbon layer formed on the carbon layer support 32 maybe adjusted using a carbon layer control 140. In at least oneembodiment, the carbon layer control 140 may be formed from one or moreagitating devices, such as a hinge arm, for shaking the carbon layersupport 32 such that ash can fall through the carbon layer support 32and collect in the ash collection zone 46. The ash may be removed fromthe ash collection zone 46 when necessary through one or more valvesenabling ash to be removed without creating unregulated flow of ambientair into the ash collection zone 46.

The gasification system 10 may be shutdown by first allowing all of thefuel in the fuel inlet conduit 52 to be used in the reactor vessel 16without replenishing the fuel. In at least one embodiment, this entailsceasing the deposit of fuel in the fuel inlet conduit 52 about 90minutes before the desired shutdown time. As syngas production ceases,the diesel fuel consumption will increase as regulated by the governoron the diesel engine. When syngas delivery is too low for desiredoperation, the electricity and fuel to the plasma torches 22 may beshutoff, and the load from the generator may be disconnected. The dieselengine 108 may be operated at idle until the reactor vessel 16 is burnedclean, and the reactor temp drops to about 300 degrees Celsius. Allcooling systems within the gasification system 10 should be operateduntil the reactor vessel 16 is cold to prevent damage. Filters may bereplaced as needed.

It will be understood that the invention is not limited to the specificdetails described herein, which are given by way of example only, andthat various modifications and alterations are possible within the scopeof the invention as defined in the following claims.

1. A plasma assisted gasification reaction chamber, comprising: areactor vessel having at least one fuel inlet, a pyrolysis reactionzone, a combustion reaction zone, a carbon layer support, and a syngascollection chamber, wherein the pyrolysis reaction zone is positionedupstream of the combustion reaction zone and includes at least oneplasma torch, the combustion reaction zone is positioned upstream ofcarbon layer support, and the carbon layer support is positionedupstream of the syngas collection chamber; a syngas heater with an inletin fluid communication with the syngas collection chamber, wherein thesyngas heater is positioned in the pyrolysis reaction zone such thatheat from the pyrolysis reaction zone heats syngas flowing through thesyngas heater.
 2. The plasma assisted gasification reaction chamber ofclaim 1, wherein the syngas heater is formed from at least one conduithaving at least one inlet in direct fluid communication with the syngascollection chamber.
 3. The plasma assisted gasification reaction chamberof claim 2, wherein the conduit extends from the syngas collectionchamber, through the carbon layer support, through the combustionreaction zone and into the pyrolysis reaction zone.
 4. The plasmaassisted gasification reaction chamber of claim 3, wherein the at leastone conduit forming the syngas heater is formed from a conduit that ispositioned at least in part radially outward from a fuel inlet conduitforming at least a portion of the at least one fuel inlet of the reactorvessel.
 5. The plasma assisted gasification reaction chamber of claim 4,wherein the at least one conduit forming the syngas heater has at leastone outlet in the pyrolysis reaction zone.
 6. The plasma assistedgasification reaction chamber of claim 5, wherein the at least oneconduit forming the syngas heater has a plurality of outlets in thepyrolysis reaction zone.
 7. The plasma assisted gasification reactionchamber of claim 5, wherein the at least one outlet in the pyrolysisreaction zone is formed from a plurality of exhaust orifices positionedin each of the at least one outlet.
 8. The plasma assisted gasificationreaction chamber of claim 5, wherein the at least one conduit is formedfrom at least one exhaust conduit having a support bearing that bears onan outer surface of the fuel inlet conduit forming at least a portion ofthe at least one fuel inlet of the reactor vessel.
 9. The plasmaassisted gasification reaction chamber of claim 8, wherein the at leastone exhaust conduit is formed from a plurality of exhaust conduits, eachextending radially outward with an axially extending portion having asupport bearing that bears on the outer surface of the fuel inletconduit forming at least a portion of the at least one fuel inlet of thereactor vessel.
 10. The plasma assisted gasification reaction chamber ofclaim 9, wherein the plurality of exhaust conduits form four exhaustconduits extending radially outward from a central conduit that is influid communication with the syngas collection chamber, wherein the fourexhaust conduits are equally spaced from each other.
 11. The plasmaassisted gasification reaction chamber of claim 1, wherein the pyrolysisreaction zone is positioned between an inner surface of the reactorvessel and an outer surface of a conduit forming a fuel inlet, whereinthe combustion reaction zone is defined by at least one rotatable burneron an upstream side of the combustion reaction zone, wherein therotatable burner is configured to rotate within the reactor vessel toreduce the formation of burn channels in fuel held in the reactorvessel, and further comprising an ash collection zone positioneddownstream from the carbon layer support.
 12. The plasma assistedgasification reaction chamber of claim 1, wherein the at least oneplasma torch extends partially radially inward and is positionednontangential and nonradial in a plane orthogonal to a longitudinal axisof the reactor vessel, and the plasma torch is positioned in adownstream direction nonparallel to the longitudinal axis, thereby,during use, forming a helical pathway of pyrolysis gas within the fuelcontained in the reactor vessel.
 13. A plasma assisted gasificationreaction chamber, comprising: a reactor vessel having at least one fuelinlet, a pyrolysis reaction zone, a combustion reaction zone, a carbonlayer support, and a syngas collection chamber, wherein the pyrolysisreaction zone is positioned upstream of the combustion reaction zone andincludes at least one plasma torch, the combustion reaction zone ispositioned upstream of carbon layer support, and the carbon layersupport is positioned upstream of the syngas collection chamber; whereinthe pyrolysis reaction zone is positioned between an inner surface ofthe reactor vessel and an outer surface of a conduit forming a fuelinlet, wherein the combustion reaction zone is defined by at least onerotatable burner on an upstream side of the combustion reaction zone,wherein the rotatable burner is configured to rotate within the reactorvessel to reduce the formation of burn channels in fuel held in thereactor vessel, and further comprising an ash collection zone positioneddownstream from the carbon layer support; and a syngas heater with aninlet in fluid communication with the syngas collection chamber, whereinthe syngas heater is positioned in the pyrolysis reaction zone such thatheat from the pyrolysis reaction zone heats syngas flowing through thesyngas heater; wherein the at least one conduit forming the syngasheater is formed from a conduit that is positioned at least in partradially outward from a fuel inlet conduit forming at least a portion ofthe at least one fuel inlet of the reactor vessel; wherein the at leastone conduit forming the syngas heater has at least one outlet in thepyrolysis reaction zone.
 14. The plasma assisted gasification reactionchamber of claim 13, wherein the syngas heater is formed from at leastone conduit having at least one inlet in direct fluid communication withthe syngas collection chamber.
 15. The plasma assisted gasificationreaction chamber of claim 14, wherein the conduit extends from thesyngas collection chamber, through the carbon layer support, through thecombustion reaction zone and into the pyrolysis reaction zone.
 16. Theplasma assisted gasification reaction chamber of claim 13, wherein theat least one conduit forming the syngas heater has a plurality ofoutlets in the pyrolysis reaction zone.
 17. The plasma assistedgasification reaction chamber of claim 13, wherein the at least oneoutlet in the pyrolysis reaction zone is formed from a plurality ofexhaust orifices positioned in each of the at least one outlet.
 18. Theplasma assisted gasification reaction chamber of claim 13, wherein theat least one conduit is formed from at least one exhaust conduit havinga support bearing that bears on an outer surface of the fuel inletconduit forming at least a portion of the at least one fuel inlet of thereactor vessel.
 19. The plasma assisted gasification reaction chamber ofclaim 18, wherein the at least one exhaust conduit is formed from aplurality of exhaust conduits, each extending radially outward with anaxially extending portion having a support bearing that bears on theouter surface of the fuel inlet conduit forming at least a portion ofthe at least one fuel inlet of the reactor vessel.
 20. The plasmaassisted gasification reaction chamber of claim 19, wherein theplurality of exhaust conduits form four exhaust conduits extendingradially outward from a central conduit that is in fluid communicationwith the syngas collection chamber, wherein the four exhaust conduitsare equally spaced from each other.
 21. The modular, syngas powered,power generation system of claim 13, wherein the at least one plasmatorch extends partially radially inward and is positioned nontangentialand nonradial in a plane orthogonal to a longitudinal axis of thereactor vessel, and the plasma torch is positioned in a downstreamdirection nonparallel to the longitudinal axis, thereby, during use,forming a helical pathway of pyrolysis gas within the fuel contained inthe reactor vessel.